Method of producing heat-fused cast refractory product having cao and mgo as its principal constituents



United States Patent Office 3,523,804 Patented Aug. 11, 1970 3,523,804 METHOD OF PRODUCING HEAT-FUSED CAST RE- FRACTORY PRODUCT HAVING CaO AND MgO AS ITS PRINCIPAL CONSTITUENTS Yukio Fukatsu, 1439 Z-chome, Setagaya, Setagaya-ku, Tokyo, Japan, and Kazuyuki Iida, 2441 Nakatohara, Kawashima-cho, Hodogaya-ku, Yokohama, Japan No Drawing. Filed Aug. 8, 1967, Ser. No. 659,032 Int. Cl. C04b 35/04, 35/06 US. Cl. 106-58 9 Claims ABSTRACT OF THE DISCLOSURE Cast refractory product of CaO-MgO system, in which the content of CaO plus MgO is above 85% by weight analysis and SiO content is below 8% by weight analysis, is produced by melting raw refractory materials of various kinds in the presence of metal, casting and resolidifying the molten materials.

BACKGROUND OF THE INVENTION Field of the invention The present invention relates to a method of producing basic heat-fused cast refractory products, and more particularly, relates to a method of producing heat-fused cast refractory products containing CaO and MgO as the principal constituents.

Description of the prior art In general, a refractory product having CaO and MgO as its principal constituents has been widely known as a dolomite refractory product since old times. Dolomite refractory product is used, particularly for making steel furnaces, e.g., oxygen steel making furnaces, basic open hearth furnaces, Bessemer converters, electric furnaces, and ladles. In addition, they have been widely adopted for the use in the manufacture of cement firing kilns and also furnace materials useful in the chemical industry.

However, these dolomite refractory products are nonuniform in composition and unstable in the structure, because they are bonded refractory products which are manufactured by firing or unfiring. They entail chemical and mechanical defects in the bonding part. Further, an important problem lies in the fact that since the dolomite bonded refractory product possesses high permeability, it is likely to absorb moisture or humidity and frequently causes slaking.

On the other hand, when such bonded refractory products are heat-fused and cast, they are found to show better properties.

As is well known, a fused, cast refractory is the type of refractory product commonly produced by melting refractory material of desired composition and then casting the molten refractory material into a mold to solidify and form any particular shape desired as predetermined by the mold cavity.

As fused cast refractory materials, materials of A1 O -SiO system, a MgO-Al O system, a Al O -ZeO -SiO system and a Cr O -Al O MgO-Fe O system are presently and been widely used.

However, fused-cast refractory products having as principal constituents CaO and MgO have not yet been adopted practically, despite the fact these products are provided with distinct and particular characteristics in comparison with bonded refractory products.

In regard to heat-fused cast refractory products of a CaO-MgO system, a few compositions have hitherto been made but have not yet proved good enough for use.

This is due to the phenomenon called bulge (which is further described later), which does not substantially take place in cast refractory products of other systems.

This problem is the one which could not be solved, for instance, by the limitation of principal constituents consisting of CaO, MgO, SiO nor by the addition of specific oxides.

Bulging is the convexity phenomenon which occurs chiefly in the neighbourhood of the center of cast refractory material by some causes (see various possible causes shown in the description of examples set forth hereinafter). This phenomenon becomes an important cause which prevents cast products of the CaO-MgO system from becoming dense, concretely speaking especially since the phenomenon makes cast refractory products porous and degrades corrosion resistance against the molten slag.

BRIEF SUMMARY OF THE INVENTION The present invention was completed after numerous experiments were made with regard to the aforementioned problems.

Namely, the present invention solves various problems which arise in cast refractory products, by imparting each condition described below:

(a) Metal is to be added as an addition agent or agents;

(b) The metal to be added is one or more than two of metals selected from the group consisting of Fe, Al, Cr, Ti, Mg, Ca, Sn, Zr, Mn, Si, Co and Ni;

(c) The proportion of metal to be added is to be selected so that each proportion of metals may be in a predetermined range, at the time of the production of heat-fused cast refractory products of CaO-MgO system which contain at least above of CaO=+MgO and below 8% of SiO on the basis of an oxide analysis, wherein CaO ranges from to 10% of CaO+MgO and MgO ranges from 10 to 90% of CaO-I-MgO.

Furthermore, according to the present invention, it has also been found that a further better result can be obtained by using halides, together with the addition of metals.

A principal object of the present invention is to provide heat-fused cast refractory products of CaO-MgO system free from the bulge phenomenon.

. Another object of the present invention is to provide dense heat-fused cast refractory products of CaO-MgO system.

Still another object of the present invention is to provide fused cast refractory products of CaO-MgO system having superior corrosion-erosion resistance.

A further object of the present invention is to provide fused cast refractory products of CaO-MgO system having superior slacking resistance.

Still further object of the present invention is to provide fused cast refractory products of CaO-MgO system having excellent compressive strength.

Yet another object of the present invention is to provide fused cast refractory products of a high purity CaO-MgO system.

7 Other objects and advantageous features will be apparent from the following description of the invention.

DETAILED DESCRIPTION OF THE INVENTION INCUDING PREFERRED EMBODIMENTS As is well known, fused cast refractory products are of a texture wherein various ra-W refractory materials are completely melted and resolidified to produce various interlocking crystals, the clearances of which are filled with a glassy phase and/or fine crystals, respectively called a matrix. In the refractory products produced in the present invention, a greater proportion of crystals is crystal orraw"refractory'rhaterizils, workingcond'ition or the like;

there may be produced crystals of 3 CaO-SiO 2 CaO-SiO 3 CaO-2SiO or CaO-MgO-SiO Moreover, 2 CaO-MgO-Fe O or the like is produced in case of the presence of Fe.

Comparing a cast refractory product with a bonded refractory product, the former is generally-more superior to the latter in corrosion resistance and slaking resistance. However, in castings of refractory products, the matrix portions filling clearances between crystals are in general liable to be corroded by various corrosion agents. Therefore, every possible care should be paid to the matrix portion in order to sufficiently utilize characteristic features of crystal parts.

In the present invention, it has been found from numerous experiments that strict limitation is necessary with regard to SiO Fe O (FeO) or the like as components to form their matrix. Namely, in fused cast refractory products produced by the present method, the total of C210 and MgO should be above 85% by weight (in the present specification, all proportions will be shown hereinafter by weight proportion, except where otherwise stated), preferably above 90%. According to the present method, SiO does not affect corrosion resistance more remarkably than Fe O (it exists also in the form of FeO as Fe oxide, and the state of presence in cast product varies with the difference in condition of melting, and in the present invention, all Fe is converted into Fe O and shown in the form of Fe O but maximum of SiO is 8% in the cast product, and particularly it needs to be limited from 0.5 to 5%.

On the other hand, Fe O is below 6%, and particularly preferable from 0.5 to 3.0%. Namely, the excessive presence of SiO and/or Fe O increases excessively the necessary amount of matrix formation and low melting substance, causing a lowering of the corrosion resistance of the refractory product.

Thus, the total of CaO and MgO should be above 85%, particularly it should be above 90%, and limitation is also required respectively to CaO and MgO. For instance, when MgO is excessive, the melting point becomes remarkably high at the time of the fusion and it becomes substantially difiicult from both operational and technical points of view.

On the other hand, with respect to the extreme case of CaO, up to nearly 100% of CaO can be made present by removing the impurities inevitably entered from raw material, but there is a problem of slaking phenomenon. Namely, with the cast product, even if nearly 100% of CaO is present, its slaking phenomenon occurs thin from the surface and slowly. Accordingly, there is no occurrence of such a phenomenon as moisture from water vapor penetrating into the interior of the refractory product and thus, effecting disintegration not only at the surface, but also largely from the interior portion, as seen in case of the bonded refractory products. Further, in order to prevent the slaking phenomenon from occuring on the outer surface, a short interval of reservation after production, or the preservation after necessary surfacetreatment, becomes necessary.

From the above-mentioned facts, it is preferable that for the proportions of CaO and MgO in the cast product, CaO range from 90 to 10% by weight of the total of CaO and MgO, while MgO ranges from 10 to 90% by weight of the total, and preferably CaO ranges from 75 to 35%, and MgO ranges from 25 to for the total of CaO and MgO. Furthermore, for slaking resistance, according to the method of the present invention, it is a fundamental problem, to control each component in the above-mentioned ranges, although it may be also improved to some extent by substances to be added as described below.

In case where the corrosion resistance and slaking resistance are essentially considered, such a condition is required. Moreover, it has been found from the results "of 'var'ious experime'nts that on these fundamental bases the accomplishment of the dense cast product including the aforesaid objects can be more accelerated.

The present invention successfully prevents the above described cast refractory product of CaO-MgO system from bulging by using a metal or metals as addition agents upon the basis of the limitation of these components.

In the present invention, addition agents such as metals, halogen components and oxides are generally added to the batch of various raw refractory materials and are mixed with these raw materials, and are sometimes added to the melt material in an electric furnace. In any case, additive agents as mentioned above are added before casting in the mold.

In the following, the present invention will be further described with reference to examples which are illustrative but not limitating. Furthermore, in this specification, the amounts of addition agents to be added, such as metals, raw halogen materials and oxides are shown in parts by weight relative to parts of all raw refractory materials except addition agents, calculated as oxide.

Example 1 Raw refractory materials used in the present invention are chiefly limestone, unslaked lime, slaked lime, dolomite, magnesia clinker, magnesite, magnesium hydroxide, dunite, serpentine, talc, wollastonite and quartzite or the like, among which the most optimum are unslaked lime, magnesia clinker and dolomite. Several analytical values of raw materials are as follows:

Unslaked lime Percent CaO 90-97 MgO 0.8-2.1 Si0 0.9-5.0 A1 0 0.4-2.8 F6203 Others below 0.5

Magnesia clinker Percent MgO 85-96 CaO 1.0-2.6 Si0 2.3-5.5 F6203 A1 0 0.3-2.0 Others below 0.5

Calcined dolomite Percent MgO 31-40 CaO 56-66 SiO 1.1-3.5 F6203 A1 0 0.1-0.5 Others below 2.5

Quartzite Percent SiO 97-99 F203 0.3-0. A1 0 0.4-1.0 Others below 2.5

All sorts of raw materials were respectively proportioned to provide the desired final composition, and then charged in-an electric arc furnace. Generally the electric furnace is lined with a refractory material similar to the refractory material to be melted.

The raw refractory materials charged in the electric arc furnace were melted for 1.5 hours at 3000" C. max. The molten raw refractory materials are cast into a hexahedron-shaped mold having an inner voliune of mm.

x 230 mm. x 540 mm. As a material of the mold, graphite or cast iron is generally used.

' Melt analyses are as follows:

(NOTE 1): when it is intended to get a predetermined shape of cast product for an object of the invention, the rate of bulging indicates the degree of the convexity of the volume of the cast products and is in the value of TABLE 1 Sample MgO 050 S102 F5205 A1205 Others wxloo P 1- 50.32 47. 53 1.57 0.40 0.11 0.07 V P 2 a1. 71 62.85 3.82 1. 31 0.20 h i In the present specification, specimens of the fused 0 volume of the Oblect and cast product are shown by P and S, but these shown by V volume of the Pmduct- P are for the sake of comparison an Outside t g (NOTE 2): the corrosion resistance was tested by the of the subject of the present invention. Accordingly, f ll i th d; Table 1 does ot Sh the Cast Product Of the P16551113 A crucible consisting of each specimen and converter invention. These P1 and P2 are of superrorpropertres l ((330 52.0%, S10 12.7%, A1 0 3.2%, MgO- 2.1%, and possible to be employed for certaln uses. However, M110 6 8%,.P O 2.7%, Fe O 22.8%) was put in said they are not sufi'icient for developlng fi t ly e chafcrucible, which was rotated at speeds of 3 r.p.m. for 10 acteristic feature as a cast refractory product. Th1s fact h Th t shown i T bl 2 was th d h of corrosion is PP from the compaflson of them Wlth the of slag in mm. unit when the abovementioned operation fractory product cast in accordance with the present was i d out at 1,700 c invention. (NOTE 3): the sample was respectively placed in the Analytical values, together with klDdS of metals used room (temperature C., humidity 65%) and in the and proportions thereof of the cast products manufacvapor (temperature C., humidity 85%) and the petured in accordance with the present lnventlon, Whe elh riod of time until the disintegration started to occur metals are mixed with raw refractory materials as addlwas Shown b month tion agents and treated in similar steps, are shown below: a As shown in Table 3, P1 and P2 show a higher degree TABLE 2 Kinds of metals added in accordance with the present invention and the added amounts (in parts by weight relative to 100 parts of all raw materials except the metals, calculated as Specimen CaO MgO S104 F8203 A1203 Others id s1-1 37.80 58.01 2.06 1.94 0.10 0.09 Fe, 04part 47.75 48.44 2.10 0.77 0.91 0.03-. 4 04 57.32 36. 06 0.87 .66 4- Fe, 0.5 part+Al, 2.0 parts. 50.07 40.28 4.02 1.09 0.11 S1102, 4.37; others 0.05 Sn, 4.0 parts. 51.14 34.03 2.85 0.75 0.09 (31.03, 1.01; others 0.13.. St, 0.5 part+Cr, 0.8 part.

72.05 21.27 2.00 0.81 0.15 2105,3511; others 0.14... Zr, 3.0 arts. 50. 43 4e. 1. 59 1.01 0.13 M n0z, 2.20; others 0.88 Mn, 1.4 parts. 1s. 49 80.35 1.75 1.45 0.11 N10, 2.45; others 0.40.... Ni, 2.4 parts. 42.70 51.26 1.88 1.15 0.11 000,237; others 0.53... 00, 2.3 parts. 47.85 45.61 5.22 0.85 0.09 0-38 Si, 1.2 parts. 54. 03 40.13 1.51 1.35 0.13 0 403, 2.54; others 0.31.- Cr, 2.0 parts. 31. 62.37 1.05 1.49 0.14 T101, 2.72; others 0.45 Ti, 1.5 parts.

Analytical values stated herein are all shown in oxide form, but partly contained in the cast product in the form of metal, but all such are shown as converted in oxide.

All metals shown in examples have a high purity of over 97% and have been mixed in a batch of raw materials as powders below 48 mesh.

Further, metals are generally blended in powders. Sometimes, they are used in the form of small pieces, fine chips, and small masses.

Various properties of the cast products shown in Table 1 and 2 are summarized in Table 3.

of bulge in comparison with S1-S12. Accordingly, the former are evidently inferior to the latter in both corrosion and slaking resistance.

Considering the effect of the addition of metal in the field of cast refractory products, the eifect can be clarified only by practical experiments, and the theory and experimental results are not coincident. Hence, the reasons are difficult to grasp definitely, but the following matters can be considered.

Referring to the reasons for the phenomenon of bulge, the largest reasons are due to gases, such as oxygen, water TABLE 3 (Note 3) Slaking resistance (Note 1) (Note 2) in the- True Refrae- Rate of Corrosion Compressive specific toriness bulging resistance Room Vapor strength Specimen gravity (SK) (percent) (mm) (month) (month) (kg/cm?) 7 8 vapor or the like. The deliberation of such gases arises TABLE 4 from the difference between solubilities of gas of the melt etal: Y ercent b we ht and sol1d matenal, followed by the sol1d1ficat1on of molten M Fe n (13 55 2 materials. A relatively large cavity is believed to be form d 5 A1 in the cast refractory product due to such gases. On the Cr 2 other hand, molten substances composed of compositions, Ti such as remarkably strong basic C110 and MgO absorb M0 gases easily. Consequently, in the composition of the present invention, the evolution of gases is considered to 10 Sn 0 be remarkably high. Zr 1 Metals used in the present invention form oxides by Mn 5 reaction with gases such as oxygen or the like. Namely, Si it seems to act as a reducing agent and thereby prevents Co the cast product from bulging. 15 Ni 9 As metals used in the present invention, Fe and Al are most preferred. Moreover, Mg and Ca are used (see In the present invention, when each metal is compared Table 7), in addition to Cr, Ti, Mn, Si, Sn, Zr, Ni and by weight, the amount to be added varies depending on Co shown in Table 2. In particular, Mg and Ca are suitthe kind of metal. Accordingly, when Sn is used in a able for providing cast refractory products of a CaO- maximum, Sn is sometimes present as oxide in the order MgO system of high purity. of 15% in the cast refractory product. When considera- The effective quantity of metal to be added varies more tion is paid that the ratio of CaO-l-MgO in the cast prodor less with the kind of metals, manufacturing steps and not may be above 85%, preferably above 90% it is not the like, but is substantially similar. preferable to use an abundance of Sn.

In the case of Fe, Fe O in the cast refractory product In the present invention, it is also possible to use more is below 6.0%, preferably below 3.0% as described above. than two metals in combination. Therefore, even when Accordingly the proportion of Fe to be added as metal the amount of a certain metal to be added is below the is below 5 parts, preferably below 3.0 parts relative to 100 amount shown in Table 4, the amount is eifective if the parts of all raw refractory materials except metals, caltotal amount of more than two of metals is in the range culated as oxide, even in consideration of a part of them satisfying the above-mentioned formula. On the other being lost or diluted. hand, in regard to a certain metal, when that metal is In general, the effective amount of metal added is added up to the upper limit shown in Table 4, a simultane in the range satisfying the following formula: ous use of other metals should be avoided. In general, one

Yn kind of metal is used.

0.005(2 A 0.1 Excessive addition of metal causes inferior properties n in the refractory product. This is believed due to the fact (P y Whereln that the amount of metal remaining in the refractory each Yn, A-Wn and (1), (11), (111), (x11) means roduct as metal increases and that the oxide formed in the followmg matters: abundance causes matrix inferiority. Yn indicates the amount to be added as metal of metal 71 40 Further, alkali metal cannot be used. On the other shown in the proportion relative to parts of all raw hand, Ce, B. V or the like cannot be used in the industry,

F Y matel'lals P Calculated f l because they are expensive, but their effect is acknowl- 'w lndlcatfis fi altonfllc Welght metal and edged. The results of Fe (metallic Fe) and Al (metallic (111) (X11) mdlqate resPectlvely twelve kinds of Al) which are most preferred metals are shown in Tables metals (Fe, Al, Cr, T1, Mn, s1, Zr, Sn, Mg, Ca, Co and 45 5 and TABLE 5 Chemical Analysis Metal to be added and Specimen MgO CaO SiOg F9203 A1203 Others amount thereof 49.91 0.02 0.63 0.12 0.07 Fe, 0.05 part. 37.30 2.06 1.94 0.10 0. 09 Fe, 0.4 part. 53. 21 2.00 2.06 0.11 0.55 Fe, 1.2 parts. 20.96 5.32 2.31 1.01 0.19 Fe, #7 parts.+Al, 0.3 42.90 1.35 6.64 0.30 0.93 F515 parts. 47.20 2.05 0.30 0.09 0.19 Al, 0.02 part. 47.75 2.10 0.77 0.91 0.03 Al, 0.4 part. 53. 92 4. 39 1.07 5.75 0.06 Al, 2.5 parts. 53.75 1.42 1.04 10.63 0.16 A1, 5.1 parts. 41.50 12.30 1.69 0. 37 0.45 Fe, 0.9 part.

TABLE 6 Slaking resistance in True Refracto- Rate of Corrosion Compressive specific riness bulging resistance Room Vapor) strength Specimen gravity (SK) (percent) (mm) (month) (month) (kg/cm?) -The results in the case where Ca and Mg are used as the metal are shown in Tables 7 and 8. Mg and Ca are the metals constituting MgO and CaO which are the principal constituents of the cast refractory product. Hence, it is possible to produce cast refractory products of CaO-MgO system with high purity by using high purity raw refractory materials of C210 and MgO. Furthermore, Ca has been added in small mass to the melt material in an electric furnace afterthe fusing treatment of raw refractory materials is completed.

TABLE 7 Chemical composition of cast refractory product Metal to be added and its proportion (based on 100 Specimen MgO 09.0 $102 F9203 A1203 Others parts of new materials) 0. 69 0.98 0. 11 0.06 Mg, 1.4 parts. 2; 02 0.87 0.10 0.11 Ga, 2.3 arts.

TABLE 8 point of the order of 2500 C., as is suitable for the manu- R f C i facture of the opitmum cast product. Namely, those haloggg tg gg' igf 25222233 gtgff gg gen components which are stable even at a relatively high Specimen gravity (SK) (percent) (mm.) '(kgJemfi) temperature, are suitable. In this regard since NH C1 is S13 3,45 1 H 1,5 11,500 easy to decompose, care should be taken at the time of s14 3.40 41 1-2 1.4 1,500 use. Even when NH Cl is decomposed, Clacts as halolUp gen instantaneously and imparts the efiect to the cast roduct. EXAMPLE 2 As halogen components, F and Cl are suitable, and especially F is appropriate. As a halide, this compound is generally used as chemicals or mineral containing halogen components. In practice, CaF (fluorite) is the most suitable. On the other hand, even when halogen itself is TABLE 9 Analysis of cast product Addition agents and added amount (based on 100 parts Specimen MgO CaO- S102 FezOa A120 F 01 Others of all raw materials) 1. 61 1.90 0. 10 1. l7 0. 55 Fe, 1.6 parts+fiuorite (CaFz,

98.1 percent) 2.8 parts. 2.05 0. 78 1. 89 0. 33 0. 12 A1, 1.0 part+MgClg, 1.8 parts. 1. 84 0. 85 0.08 0. 90 0. 69 Mg 1.0, part+CaF:, 2.8 parts. 0. 68 2. 26 1. 72 2. 44 0. 05 Fe, 0.9 part+AlFa, 4.8 parts. 1. 14 1. 03 0. 96 0. 20 0.09 A1, 0.3 part+Fe, 0.5 part +C8Clz, 1.4 parts.

TABLE 10 Slaking resistance in- True Refrac- Rate of Corrosion Compressive specific toriness bulging resistance Room Vapor strength Specimen gravity (S K) (percent) (mm) (month) (month) (kg ./cm.

3. 44 1 41 Below 1%- 1.5 9. 9 3. l 1, 500 3. 38 1 41 o 1. 6 9. 8 3. 4 l 1, 500 3. 1. 6 10. 1 3. 6 1 1, 500 3. 45 1. 6 10. 2 3. 7 1 1, 500 3. 46 l. 5 9. 9 3. 6 1 1, 500

In the production of cast refractory products of Ca0- MgO system, it is most desirable to jointly utilize the effects of metal and the eifects of halogen. The effect is especially high when Fe is used as metal and CaF (fluorite) as halogen.

Here, considering the effects of halogen, the effect of halogen is not'evident as much as the effect of metal. Now, the following can be considered. Namely, the metal soto-speak is considered to the effect-that it reacts with gas such as oxygen in the molten substance as a reducing agent to prevent the bulge, whereas the halogen is exist- During manufacture, raw halogen material is decomposed,

with the result that halogen dissipates partially. How ever, the amount of halogen remaining in the cast product is seldom reduced to below 40% in the case of fluoride on the basis of halogen. In an addition where the residual amount is below 0.1%, the effect is less, while an excessive addition degrades the property of the matrix. EXAMPLE 3 The results obtained in simultaneous use of metal and oxide in a similar method are shown in Tables 11 and 12.

TAB LE 1 1 Analytical value of cast refractory product Addition agents and amount added (based on 100 parts of Specimen CaO MgO S105 FeaO; A1203 Others raw materials) 47. 08 2.03 0. 89 0. l1 M1102, 2.60; 090:, 0.98; others, 0.06. e09, 1 part+Mn, 2.2 parts. 33.17 4. 86 2. 32 0.08 T1014, 2.25; others, 0.52 T102, 2.3 parts+Si, 2.3 parts. 44. 64 1. 64 0. 62 3. 76 V05, 1.64; others, 0.24 V105 1.8, parts-H11, 2.2 parts. 45. O9 1. 42 1. 33 0. 08 B203, 5.30; others, 0.49 Boric acid, 10.1 parts-i-Fe, 0.8

part. 58. 09 1. 69 2. 41 0. 09 CIzOa, 3.69; others, 0.18 GU03, 3.8 parts+Fe, 1.4 parts. 39. 36 3.88 1. 37 0. 12 ZrOz, 4.65; S1102, 0.46; others, 0.10"... ZrOz, 0.9 part-l-sno 0.5; part +Z1Og, 3 parts.

TABLE 12 Slaking resistance in- True Reirat'r Rate of Corrosion Compressive specific toriness bulging resistance Room Vapor strength i n gravity (SK) (percent) (rnrn.) (month) (month) (kgJcmfl) 3. 45 1 41 1-2 1. 8 11. 3. 8 1 1, 500 3.46 1 41 1-2 2. 0 10. 3 3. 6 1 1, 500 3. 44 1 41 l-2 2. 0 10. 1 3. 1 1, 500 3. 42 1 41 1-2 1. 6 11. 2 3. 9 l 1, 500 3. 45 1 41 1-2 1. 8 10.9 3. 7 l 1, 500 3. 46 41 1-2 1. 9 11.4 4. 0 1, 500

As is apparent from Table 12, each specimen from S to S shows an excellent slaking resistance. The greater part of metals added according to the present invention is present in the cast product as oxide. As a consequence, it is quite obvious that the addition of the metal would contribute to the elimination of bulge from the cast product and simultaneously to improvement in the slaking resistance of the cast product. As a result of a series of experiments, it has been found that the most excellent slaking resistance can be imparted to the cast product by the presence of one or more than two oxides, such as SnO CeO ZrO T102, V 0 B 0 and Cr O The effect of oxide is considered to be based on the stabilization of free CaO existing in the cast product.

The effect of the oxide can be recognized when the aforesaid oxide is present from 0.3 to 7.5% in the cast product. The presence of 0.5 to 5.4% gives an especially favorable result.

According to the present invention, various shaped cast refractory products can be obtained.

The cast refractory products cast in accordance with the present invention may also be used after pulverization. Namely, pulverized raw materials are preferred as raw materials for fired or unfired refractory products. Further, the pulverized raw materials are effectively used as a stamping material or raw material for mortar, in place of natural dolomite.

What we claim is:

1. A method of producing dense heat-fused cast refractory product containing oxides of calcium and magnesium as its principal constituents, comprising the steps of heat-fusing, casting and resolidifying raw refractory materials in which chemical analytical values are 90 to 10% CaO, 10 to 90% MgO, 0.5 to 5% SiO and 0.5 to 3% Fe O the total of said CaO plus MgO being above 85%, by weight in the cast refractory product, characterized by adding at least one metal selected from the group consisting of Fe, Al, Cr, Ti, Mg, Ca, Sn, Zr, Mn, Si, Co and Ni to the said raw refractory materials at least before casting and in a proportion that the amount of said metal should satisfy the formula:

n=(i), (ii), (xii), wherein:

2. A method according to claim 1, wherein the chemical analytical values of CaO is from 75% to 35% by weight of the total of CaO+MgO.

3. A method according to claim 1, wherein also is added at least before casting, a halogen component, said halogen component being present in the cast refractory product as halogen in an amount of from 0.1% to 3% by weight.

4. A method according to claim 3, wherein the halogen is a member selected from the group consisting of fluorine and chlorine.

5. A method according to claim 1, wherein chemical analytical values are above of the total of CaO plus MgO, by weight, in the cast refractory product.

6. A method according to claim 2, wherein said metal is Fe and chemical analytical values are above 90% of the total of CaO plus MgO, by weight, in the cast refractory product.

7. A method according to claim 2, wherein said metal is Al and chemical analytical values are above 90% of the total of CaO plus MgO, by weight, in the cast refractory product.

8. A method according to claim 3, wherein said metal is Fe and said halogen is fluorine.

9. A method according to claim 1, wherein there is also added at least before casting about 0.3%7.5% of, at least one oxide selected from the group consisting of CeO zl'og, T102, S1102, V205, B203 and CI'203, weight, in the cast refractory product.

References Cited UNITED STATES PATENTS 2,113,818 4/1938 Sullivan 10661 2,310,591 2/ 1943 McMullen 106-61 3,030,228 4/1962 Hernandez et a1. 106-58 3,223,758 12/ 1965 Fischer 106-63 3,262,795 7/ 1966 Davies et al. 106-58 JAMES E. POER, Primary Examiner U.S. Cl. X.R. 

